Problem in Germany is, it has to have an "E" and a number on it to certify that it has been approved for road use somewhere in the EU. Weird I know... The other option would be to get a custom certification but that would have to include a noise measurement, you're looking 150-200€ there
Not 100% sure on the situation in the UK, but I think it wouldn't pass an MOT here either, due to the lack of that number... Yes, you could be cheeky and use a dremel to write one on it - but with that unique design nobody would believe that

Well , The bottom line is you couldnt no E mark or nout .. however , as long as a it doesnt say Not for road use , Or A Racecan , they may let u off ,

Mhmm Wouldnt pass a mot tho   

I've almost got it solved.  I have a discussion going in another thread

http://gstwins.com/gsboard/index.php?topic=40776.20

I've lifted the DJ needle to the 3rd slot, and went back down to the 140's, with 4.25 turns out.  Everything seams fine except I still have a bad flat spot if I go full throttle.  I don't know why.  I did a plug chop at full throttle and it looked pretty good with the 140's, but maybe I'm wrong.

If anyone knows why I have a flat spot still, that would be great!

My muffler is no more.  Yesterday on my way home from work, the metal sheered, and the muffler went rolling into the intersection after taking off from a red light.  Got run over at least a few times, and is unrepairable.  the welds were fine, the actual metal piece that I purchased sheered in the center of it.  It almost looks like the back of my muffler was stepped on and broken on purpose.  Very weird.  It shouldn't have done this on it's own.  I thought I was done with building this muffler; all was well and I loved the sound, but now it's back to the drawing board.  I'm not going to make it exactly like the first one, because it was just too much work, and I don't want to go through all that again.  Hopefully I'll get it done this weekend, and I'll try to post up new pictures/video and all the good stuff of the new muffler build.

Here is my new vision for the replacement exhaust.  Let me know what you think.  (and I know you all are going to say it will be loud, but we'll see.  I just need it a little quieter than it is now, so this should work)

Sorry to hear about the mishap. Just read this thread...nice looking pipe.  I'm impressed.  I can't give too much input of the mechanics of your new design, not really my strong suit.  But best of luck.  Make sure to keep us update!! 

I worked on the muffler this weekend.  Got it ridable again, but the new baffle is too restrictive, so I've got to modify it a bit, and I'll give an update.  It really holds the bike back, and it's way too rich, so opening it up some will help.

The sound is actually slightly quieter than my previous pipe.  Probably because it's more restricted, but I'll see how it is once I open it up a bit.  It looks great though.  a lot smaller than the old pipe, and half the weight.  This thing probably only weighs about 1/2 pound, and the stock exhaust was 10 pounds.

I'll post some comparative pictures of the old pipe and the new pipe once it's done.

I've modified the new baffle, and WOW!  This new pipe is less restrictive than the previous pipe, and it shows it.  It feels perfectly matched with the jetting, and boy does she fly now.  The new pipe is louder than the previous one as well now, though.  Might be a bit too loud for my neighbors, but I don't think it's on the illegally loud side.  I might make a secondary baffle that's very unrestrictive just to throw around the gases a bit more to quiet it down some.  Even if I kept it as is, it would be fine.  I'll get pictures and video up as soon as I can.  (Don't have much time with my 5 month old daughter at home.)

Here are the links to the YouTube video's that I just posted of my new exhaust.

http://www.youtube.com/watch?v=d7lbh9jY4Zc

http://www.youtube.com/watch?v=HwcOwcOvzu0

http://www.youtube.com/watch?v=rUgM10CXDUU

And more pictures of the new exhaust...















and Stock

Dude, Ya know, that seat cutting is a good idea, took me 3-4 days to warm up to it. The front little triangle piece needs to go. It looks too much like a pu$$y ... making for the extra "girl's bike" moniker. Paint the freaking thing pink and call it a day why dont we ... Clowns at suzuki.
Cool.
Buddha.

man!! the exhaust looks great now  . and in my opinion it sounds much better than the first one.

great job!!

KaMeL

Yeah, I agree.  It sounds a lot better than the first one.  Deeper and fuller.  And at high RPM with load (actually driving), it just screams.  Sounds awesome.  As good, if not better than any 500 dollar system.

This was the look that I wanted in the first place.  Pretty much just a straight pipe that ended just past the peg.  So, since I had to build it again after the other one sheered off, I figured I'd go with what I really wanted and see if I could make it work.

That looks great!  I don't understand the trend towards gigantic exhausts.  Low and narrow looks the best.

so what did you end up doing with the jets? i am about to buy an exhaust but am handy at welding and fab. just wondering so i can order different jets. o wait you are using the dj kit right? well anyway let me know how it worked out

I have the DJ needle still.  I think I may buy some stock needles if it gives me problems, but it's pretty good right now, so it's really not getting in the way as is.  I have 140's in right now for the mains, and 40's for the pilots.  With the taper of the DJ needle, this would be about the same as 150's with the stock needle.

For a full exhaust and lunchbox, most guys on here will recommend either 147.5's or 150's.  I'd say 150's just to be on the safe side, so you're not too lean.  Of course, every bike is different, and elevation and other things affect it, so only use that as a starting point, then tune it from there on your own.

Anyone watch the youtube video's?

Quote from: The Buddha on July 16, 2008, 10:06:17 AMThe front little triangle piece needs to go. It looks too much like a pu$$y

So when you're riding it, it looks like you're rubbing your crotch against a pu$$y.  What's the problem?   

Since it's been gone, it definitely gives more room for your junk up front.  Looks a lot better too.